When maintenance is indicated, it should be performed by trained
persons having proper equipment. Fire extinguishers are pressure
vessels and must be treated with respect and handled with care.
They are mechanical devices and require periodic maintenance to be
sure that they are ready to operate properly and safely. Amerex
strongly recommends that the maintenance of portable fire
extinguishers be done by a trained professional – your local
authorized Amerex Distributor.
Amerex Corporation makes original factory parts available to insure
proper maintenance – USE OF SUBSTITUTE PARTS RELEASES
AMEREX OF ITS WARRANTY OBLIGATIONS. Amerex parts have
machined surfaces and threads that are manufactured to exacting
tolerances. O-rings, hoses, nozzles, and all metal parts meet precise
specifications and are subjected to multiple in-house inspections and
tests for acceptability. There are substitute parts available that may
be incorrectly labeled as UL component parts, some are advertised
as Amerex type. None of these meet UL requirements and all of
them voids the Amerex extinguisher warranty and UL listing. DO
NOT SUBSTITUTE.
RECHARGE FIRE EXTINGUISHERS IMMEDIATELY AFTER ANY USE
REFERENCES IN THIS MANUAL:
NFPA-10 Portable Fire Extinguishers
AVAILABLE FROM:
National Fire Protection Association
1 Batterymarch Park, P.O, Box 9101
Quincy, MA 02269-9101
CGA C-1 Methods for Hydrostatic Testing of
Compressed Gas Cylinders
CGA C-6 Standard for Visual Inspection of
Compressed Gas Cylinders
Compressed Gas Association, Inc.
4221 Walney Road, 5th Floor
Chantilly, VA 20151-2923
AMEREX CORPORATION – P.O. BOX 81 – TRUSSVILLE, ALABAMA 35173-0081
Phone: 205/655-3271 Fax: 800/654-5980
e-mail: sales@amerex-fire.com
Web Page: http://www.amerex-fire.com
Printed in U.S.A.
0M05616E Rev. 3/11
ABC (AMMONIUM PHOSPHATE BASE),Regular (SODIUM BICARBONATE BASE),
PURPKE K (POTASSIUM BICARBONATE BASE)
All fire extinguishers should be installed, inspected and maintained in
accordance with the National Fire Protection Association standard
titled "Portable Fire Extinguishers", NFPA-10 and the requirements of
local authorities having jurisdiction.
HIGH PERFORMANCE HEAVY DUTY INDUSTRIAL STORED PRESSURE
HAND PORTABLE DRY CHEMICAL FIRE EXTINGUISHERS – 6KG, 20 & 30 LB.
OWNERS SERVICE MANUAL
NO. 05616
INSTALLATION, OPERATING & SERVICING INSTRUCTIONS
THIS MANUAL IS ATTACHED TO EVERY NEW EXTINGUISHER SHIPPED FROM THE FACTORY. IT
CONTAINS VALUABLE INFORMATION WHICH SHOULD BE STUDIED BY EVERYONE WHO WILL USE OR
SERVICE THE EXTINGUISHER. THE MANUAL SHOULD BE STORED IN A CONVENIENT LOCATION FOR
EASY REFERENCE.
INTRODUCTION
The Amerex High Performance, stored pressure 13.2 (6kg), 20 lb. (9 kg) and 30 lb. (13.6 kg)
dry chemical fire extinguishers have been designed and manufactured to accommodate the
rigorous needs of environmental extremes and heavy industrial use. The finest materials,
workmanship and finishes have been utilized, backed by several years of development and
field testing to insure many years to trouble free fire protection.
These extinguishers operate at a 240 psi (1655 kPa) pressure and are intended for use by
trained fire fighters. The higher discharge velocity and superior range necessary for quick
extinguishment of many industrial fire hazards dictates formal training for development of
proper fire fighting techniques and a feel for the most effective use of the extinguisher.
All sizes feature a large, durable stainless steel operating lever and carrying handle, large
brass, chrome plated operating valve, large pressure gauge with gauge guard, molded
performance discharge hose and the Amerex "Ultra" corrosion resistant paint finish over a
"galvanized" cylinder. The stored pressure design allows easy upright, squeeze grip operation,
assures a constant, instant state of readiness, and minimizes operating parts and cuts down on
maintenance costs. Amerex is confident in the superior features of these products and have
extended our warranty to 12 years to prove it.
EXTENDED (TWELVE YEAR) LIMITED WARRANTY
Amerex warrants its High Performance fire extinguishers to be free from defects in material and
workmanship for a period of twelve (12) years from the date of purchase. During the warranty
period, any such defects will be repaired or the defective extinguisher replaced if only factory
replacement parts and recommended service equipment have been used to service the
extinguisher. Excluded items: pressure gauge and hose, nozzle assembly (these items carry
the standard Amerex 6 year warranty).This warranty does not cover defects resulting from
modification, alteration, misuse, exposure to unusually corrosive conditions nor improper
installation or maintenance. All implied warranties, including, but not limited to, warranties of
fitness for purpose and merchantability, are limited to the time periods as stated above. In no
event shall Amerex Corp. be liable for incidental or consequential damages. Some states do
not allow limitations on how long an implied warranty lasts or the exclusion or limitation of
incidental or consequential damages, so that the above limitations or exclusions may not apply
to you. Amerex Corp. neither assumes nor authorizes any representative or other person to
assume for it any obligation or liability other than expressly set forth herein. This warranty
gives you specific legal rights, and you may also have other rights which may vary from state to
state. To obtain performance of the obligation of this warranty, write to Amerex Corp., P. O.
Box 81, Trussville, AL 35173-0081 for instructions.
1
AMEREX CORPORATION DOES NOT SERVICE, MAINTAIN OR RECHARGE FIRE EXTINGUISHERS.
THIS MANUAL IS PUBLISHED AS A GUIDE TO ASSIST QUALIFIED SERVICE PERSONNEL IN THE
INSPECTION, MAINTENANCE AND RECHARGE OF AMEREX FIRE EXTINGUISHERS ONLY. NO
INSTRUCTION MANUAL CAN ANTICIPATE ALL POSSIBLE MALFUNCTIONS THAT MAY BE
ENCOUNTERED IN THE SERVICE OF FIRE EXTINGUISHERS. DUE TO THE POSSIBILITY THAT PRIOR
SERVICE PERFORMED ON THIS EQUIPMENT MAY HAVE BEEN IMPROPERLY DONE, IT IS
EXTREMELY IMPORTANT THAT ALL WARNINGS, CAUTIONS AND NOTES IN THIS MANUAL BE
CAREFULLY OBSERVED. FAILURE TO HEED THESE INSTRUCTIONS COULD RESULT IN SERIOUS
INJURY.
AMEREX ASSUMES NO LIABILITY FOR SERVICE, MAINTENANCE OR RECHARGE OF FIRE
EXTINGUISHERS BY PUBLISHING THIS MANUAL.
PREPARING YOUR NEW EXTINGUISHER FOR USE
1. Examine the extinguisher for evidence of shipping damage. Notify the delivering carrier
immediately if any damage is discovered.
2. Check to insure that the hose connection to the operating valve is tight.
3. The ring (safety) pin should be installed in the operating valve and the lockwire (tamper)
seal intact.
4. This extinguisher is shipped from the factory fully charged. Visually inspect the pressure
gauge – the pressure should be in the green zone (240 psi ± approx. 10 psi range). The
most accurate method to determine if the extinguisher is filled with the proper amount of
chemical is to weigh the unit. The gross weight is indicated on the nameplate (label).
NOTE:
Slight pressure variances in the gauge reading may be found if
the extinguisher has been subjected to extremes of heat or cold.
High temperatures can cause high gauge readings and low
temperatures, low readings. When in doubt, condition the
extinguisher to 70ºF (21ºC) for several hours to obtain more
accurate pressure gauge readings.
5. Record the date the unit is being placed into service on the inspection tag and attach it to
the extinguisher.
INSTALLATION
Your plant layout and particular hazards dictate the placement of fire extinguishers. Do not
place this extinguisher close to a potential fire hazard. Amerex recommends location no less
than a 50 foot distance from a potential hazard while leaving an unobstructed access. Avoid
placing it in an extremely hot or cold place. The operational temperature range for this
extinguisher is -65º to +120ºF (-54º to +49ºC). The extinguisher should be adequately
protected if temperatures outside of this range are anticipated. Keep the extinguisher clean
and free from dirt, ice, chemicals and any contaminants which may interfere with its proper
operation. Do not functionally test this fire extinguisher. (Testing or any use may cause the
extinguisher to gradually lose pressure and become ineffective.)
2
OPERATION
NOTE:
Persons expected to use this extinguisher should be trained in initiating
its operation and in the proper fire fighting technique. Familiarize all
personnel with this information before an emergency occurs.
1.
2.
3.
4.
Remove extinguisher from wall hanger or vehicle bracket.
Hold the extinguisher upright, twist and pull ring pin, snapping the plastic lockwire seal.
Stand back 15 feet from the fire and aim the nozzle at base of flames nearest you.
Sweep side to side across the base of the fire and past both edges. Progressively follow up
until the fire is extinguished. Work the fire away from you while being alert for flashbacks.
Move closer as the fire is extinguished but not so close as to scatter or splash the burning
materials.
5. When the fire is out, stand by and watch for possible reignition.
6. Evacuate and ventilate the area immediately after extinguishing the fire. The fumes and
smoke from any fire may be hazardous and can be deadly.
DISCHARGE TIME – VARIES ACCORDING TO THE MODEL
EFFECTIVE RANGE OF AGENT THROW IS 40-50 feet
INSPECTING THE EXTINGUISHER
This extinguisher should be inspected at regular intervals (monthly or more often if
circumstances dictate) to insure that it is ready for use. Inspection is a "quick check" that a fire
extinguisher is available and is in operating condition. It is intended to give reasonable
assurance that the fire extinguisher is fully charged. This is done by verifying that it is in its
designated place, that it has not been actuated or tampered with, and that there is no obvious
physical damage or condition to prevent its operation.
PERIODIC INSPECTION PROCEDURES
(Monthly or more often if circumstances dictate)
[NFPA-10] Periodic inspection of fire extinguishers shall include a check of at least the following items:
1.
2.
3.
4.
5.
6.
7.
Location in designated place.
No obstruction to access or visibility.
Pressure gauge reading or indicator in the operable range or position.
Operating instructions on nameplate and facing outward.
Safety seals and tamper indicators not broken or missing.
Examination for obvious physical damage, corrosion, leakage, or clogged nozzle.
Determine fullness by weighing.
MAINTENANCE
[NFPA-10] At least once a year or more frequently if circumstances require, maintenance
should be performed. Maintenance is a "thorough check" of the extinguisher. It is intended to
give maximum assurance that a fire extinguisher will operate effectively and safely. It includes
a thorough examination for physical damage or condition to prevent its operation and any
necessary repair or replacement. It will normally reveal if hydrostatic testing or internal
maintenance is required.
3
MAINTENANCE – SERVICE PROCEDURE
1.
Clean extinguisher to remove dirt, grease or foreign material. Check to make sure that the
instruction nameplate is securely fastened and legible. Inspect the cylinders for corrosion,
abrasion, dents or weld damage. If any damage is found, hydrostatically test to factory test
pressure 720 psi (4964 kPa), using the proof pressure method, in accordance with instructions
in C-6 and NFPA 10. See proper method of depressurizing and reclaiming chemical in
Recharge procedures.
NOTE:
WHEN CLEANING, AVOID USE OF SOLVENTS AROUND THE
PRESSURE GAUGE. THEY COULD SERIOUSLY DAMAGE THE
PLASTIC GAUGE FACE.
2.
Inspect the extinguisher for damaged, missing or substitute parts. Only factory replacement
parts are approved for use on Amerex fire extinguishers.
3.
Weigh the extinguisher and compare with weight printed in the "Maintenance" section on the
nameplate (label). Recharge extinguisher if weight is not within indicated allowable tolerances.
4.
Check the date of manufacture printed on the extinguisher label (nameplate) or inside the
bottom lip of the cylinder. The agent cylinder must be hydrostatically tested every 12 years to
the test pressure indicated on the nameplate [720 psi (4964 kPa)].
5.
Visually inspect the pressure gauge:
a. If bent, damaged or improper gauge, depressurize and replace.
b. If pressure is low, check for leaks.
c. If over pressurized (overcharged), depressurize the extinguisher and follow recharge
instructions.
6.
Check ring pin for freedom of movement. Replace if bent or if removal appears difficult.
7.
Inspect the discharge lever for any dirt of corrosion which might impair freedom of movement.
Inspect carrying handle for proper installation. If lever, handle or rivets are damaged replace
with factory replacement parts.
8.
Remove hose and horn assembly and visually inspect inside valve body. Chemical in the valve
body may indicate that the extinguisher has been partially discharged and should therefore be
recharged. Inspect the hose and horn assembly for damage and replace if necessary. Blow air
through the hose and horn to insure passage is clear of foreign material.
9.
Inspect the valve assembly for corrosion or damage to hose thread connection. Replace valve
assembly or component parts as necessary following the proper depressurization and recharge
procedures. If valve removal is necessary, complete all steps in the Recharge Procedure.
10.
Install hose and horn assembly.
11.
Record service data on the extinguisher inspection tag.
12.
If the extinguisher has been moved to perform service, replace it on the wall hanger or in the
vehicle bracket making sure it fits the bracket properly. Replace the bracket if necessary.
4
COMPLETE MAINTENANCE – SIX YEAR TEARDOWN
[NFPA-10] Every six years, stored pressure extinguishers that require a 12 year hydrostatic test
shall be emptied and subjected to the applicable maintenance procedures. When the applicable
maintenance procedures are performed during periodic recharging or hydrostatic testing, the
six year requirement shall begin from that date.
NOTE: Some states have legislation which requires "Complete Maintenance" on an
annual basis. Please contact your local Amerex Distributor to see if these requirements
apply to you. NFPA 10 recommendation requires that a "verification of service"
external collar tag be installed on the extinguisher whenever a Six Year Maintenance is
performed. The "verification of service" tag can only be installed if the operating valve
has been removed.
1. Discharge chemical and pressure into a "closed" dry chemical recovery system (several are
commercially available).
depressurized.
NOTE:
Make sure that the extinguisher is completely empty and
A "closed recovery system" is designed to prevent loss of the chemical "fines".
Loss of the "fines" could result in reduced extinguisher efficiency.
2. Clean extinguisher to remove dirt, grease or foreign material.
Check to make sure that the
instruction nameplate is securely fastened and legible. Inspect the cylinder for corrosion, abrasion,
dents or weld damage. If any of these conditions are found and you doubt the integrity of the
cylinder, hydrostatically test to factory test pressure marked on the nameplate (label), using the
proof pressure method, in accordance with CGA C-1 and NFPA 10.
NOTE:
When cleaning, avoid use of solvents around the pressure gauge. They could
seriously damage the plastic gauge face.
3. Inspect the extinguisher for damaged, missing or substitute parts. Only factory replacement parts
are approved for use on Amerex fire extinguishers.
4. Check the date of manufacture on the extinguisher label (nameplate).
Cylinder must be
hydrostatically (proof pressure) tested every 12 years to the test pressure indicated on the
nameplate (720 psi [4964 kPa]).
5. Visually inspect the pressure gauge – if bent, damaged or improper gauge replace with the proper
Amerex pressure gauge (see Parts List).
6. Check ring pin for freedom of movement. Replace if bent or if removal appears difficult.
7. Verify that no pressure remains in the extinguisher. (Operating valve and nozzle shutoff in
open position and there is no discharge).
8. Inspect the discharge lever for any dirt of corrosion which might impair freedom of movement.
Inspect carrying handle for proper installation. If lever, handle or rivets are damaged replace with
factory replacement parts.
9. Remove hose and horn assembly and visually inspect inside valve body. Chemical in the valve
body may indicate that the extinguisher has been partially discharged and should therefore be
recharged. Inspect the hose and horn assembly for damage and replace if necessary. Blow air
through the hose and horn to insure passage is clear of foreign material.
10. Disassemble valve assembly by removing downtube, spring and valve stem assembly. Remove
collar o-ring from valve
11. Complete steps 2 through 13 of Recharge Procedure.
5
RECHARGE
WARNING:
a. Before attempting to disassemble, be sure the extinguisher is
completely depressurized.
b. Never have any part of your body over the extinguisher while removing
the valve assembly.
c. Use a protective shield between you and the pressure gauge while
charging an extinguisher. Do not stand in front of the gauge if a shield
is not available.
d. Use a regulated pressurizing source of dry nitrogen only with a
minimum dew point of minus 70ºF (minus 57ºC). Set the regulator to no
more than 265 psi (1827 kPa).
e. Check and calibrate regulator gauge at frequent intervals. The regulator
gauge should be used to determine when the intended charging
pressure has been reached. Do not use the extinguisher gauge for this
purpose.
f. Never leave an extinguisher connected to a regulator of a high pressure
source for an extended period of time. A defective regulator could
cause the cylinder to rupture due to excessive pressure.
g. Do not mix types of dry chemicals in extinguishers, recharge or recovery
systems. Mixing ABC (acidic base) with Regular, Purple-K, Super-K or
Monnex (alkaline base) dry chemicals may result in a chemical reaction
capable of developing a dangerous pressure buildup.
RECHARGING PROCEDURE
1.
Perform steps 1 through 12 of the "Complete Maintenance (Six Year Teardown)" section.
2.
Thoroughly clean all parts of the disassembled valve with a soft bristle brush or soft cloth.
Blow the valve out with air or nitrogen. Inspect the spring and downtube assembly, and
replace parts if worn or damaged. Replace the valve stem and collar o-ring. Lubricate the
collar o-ring and small o-ring on the valve stem with Visilox V-711 (do not lubricate the valve
stem seal).
3.
Reassemble the valve assembly, including downtube and set aside.
4.
Remove any chemical remaining in the cylinder and check the condition. Properly dispose
of any chemical that is contaminated or caked.
5.
Inspect the cylinder interior following CGA Visual Inspection Standard C-6.
6.
Using an accurate scale, fill cylinder with the correct amount and type of dry chemical
specified on the label (nameplate). Use Amerex chemical which has been kept free of
moisture and contamination. See Warning (g) – DO NOT MIX TYPES OF CHEMICALS.
7.
Clean cylinder collar o-ring seat and collar threads with a small brush and then wipe off
surfaces with a clean cloth to remove dust. Lightly brush the collar o-ring seat with Visilox
V-711.
8.
Carefully center the downtube and install valve assembly hand tight to the cylinder (the
bottom of the valve body should touch the top of the cylinder collar). Attach the nitrogen
charging adapter to the male hose connector. Valve installation can be made easier by
tapping the sidewall of the cylinder with a rubber mallet as the downtube is eased into the
cylinder.
9.
With the extinguisher properly secured in an upright position, connect your nitrogen
pressurizing line with a quick connect to the nitrogen charging adapter. Pressurize
6
extinguisher with dry nitrogen to 240 psi. Nitrogen supply regulator should be set to no
more than 265 psi. This will insure proper aeration of the chemical.
10.
Check extinguisher for leaks by applying detecting fluid or a solution of soapy water to the
nitrogen charging adapter orifice, around the collar o-ring sealing area, cylinder welds and
gauge. Remove the pressurizing adapter.
11.
Install ring (safety) pin and lockwire (tamper) seal. Attach new recharge tag.
12.
Weigh assembled extinguisher and confirm that the total weight is within the allowable
tolerances indicated in the "Maintenance" section of the nameplate (label).
TROUBLESHOOTING GUIDE
WARNING:
Before attempting to correct any leakage problem, be sure that the agent
cylinder and hose are completely depressurized. Check to determine the
source of a leak before the extinguisher is depressurized. Leakage repairs
will require depressurization and removal of the valve assembly.
Depressurize by discharging into a Closed Recovery System or inverting
the extinguisher. After depressurizing the extinguisher and correcting the
problem, it will be necessary to clean all valve parts thoroughly.
PROBLEM
1.
2.
3.
4.
5.
Leak at collar o-ring
Leak through valve
Leak around gauge
Defective gauge
Leak in the cylinder
CORRECTIVE ACTION
Remove valve assembly, remove and
discard o-ring, clean collar and lube lightly
with Visilox V-711. Clean o-ring groove on
valve and install new collar o-ring. Lubricate
with Visilox V-711.
Check valve stem seating area for scratches
or foreign matter. Clean seating area with a
tooth brush and soft cloth. Install new valve
stem assembly.
Remove gauge*, clean threads and reinstall
using Teflon tape on the gauge threads.
Remove defective gauge* an install the
proper Amerex pressure gauge (P/N 05225
240 psi) using Teflon tape on the gauge
threads.
Contact Amerex if under warranty,
otherwise mark "REJECTED" and remove
from service or return to owner.
* Pressure gauge threads are coated with a special epoxy at the
factory. For easy removal, soak the valve assembly in hot water
(180°F) for two to four minutes. Remove gauge with a thin 7/16"
open end wrench.
7
PARTS LIST
for
6 Kg – 30 lb. Dry Chemical
High Performance Models
594
595
580
581
582
584
567
568
569
599
564
566
Item
No.
Part
No.
1
14874
05240
2
3*
3A
4
5
6
7
8
9
9A
10
10A
11
12
13
14
15
16
17
589
591
592
Description
Valve Assembly-Female Thread
Collar O-Rring
Collar O-Ring – Bulk Bag
14785
Hose & Horn Assembly-594 (.213)
14791
Hose & Horn Assembly-595 (.204)
Hose & Horn Assembly14788
580,581,582 (.250)
14790
Hose & Horn Assembly-592 (.166)
14794
Hose & Horn Assembly-599 (.149)
14787
Hose & Horn Assembly-564 (.166)
14786
Hose & Horn Assembly-566 (.157)
Hose & Horn Assembly14789
567, 568, 569, 584 (.312)
14947
Hose & Horn Assembly-589 (.213)
14948
Hose & Horn Assembly-591 (.180)
Strap & Clip Assembly (Black
14778
Plastic) ½" Hose 6 Kg & 20 lb.
Strap & Clip Assembly (Black
14871
Plastic) ½" Hose 30 lb.
06978
Hose Gasket (O-Ring)
00160
Ring Pin – Stainless Steel
00532
Chain (Nylon) for Ring Pin
01387
Lockwire Seal (Yellow)
09584
Hanger Loop w/Screw
09840
Lever & Rivet – All Models
01563
Rivet Only for Lever
09020
Handle & Rivet – All Models
01564
Rivets Only for Handle
05225
Gauge – 240 psi
Gauge Guard – Chrome Plated
09102
Brass
06093
Valve Stem Assembly
Valve Stem Assembly – Bulk Bag
05243
Valve Stem O-Ring
00383
Spring
01700
Dtube/Retainer Asy – 6 Kg
01667
Dtube/Retainer Asy – 20lb.
09583
Dtube/Retainer Asy – 30 lb.
Prot Foot Ring for Bottom of Cyl - 7"
12383
Prot Foot Ring for Bottom of Cyl - 8"
12952
Std.
Pkg.
1
24
100
1
1
1
1
1
1
1
1
1
1
1
1
24
24
24
500
6
1
24
1
24
6
1
6
96
24
6
1
1
ALL BRACKETS – SEE BRACKET PAGE
ALL FILL & HYDROTEST ADAPTERS – SEE ADAPTER PAGE
REPLACEMENT VALVE ASSEMBLIES INCLUDE VALVE
BODY, GAUGE, LEVER VLV STEM ASY, SPRING &
HANDLE
8